Stackable packaged soft-wall containers

ABSTRACT

A packaging system for soft-walled plastic containers of tapered or other non-cylindrical shapes has a supporting base to which the containers are secured, with a superposed positioning means engaging the upper portions of the containers; and load transfer spacer sheets extending upwardly in substantially coplanar relation with the tops of the containers, to support a superposed similar package, for palletizing. The package may be strapped, horizontally or vertically and used in plasti-wrapped multi-tier pallet loads. The supporting base may be a tray, which can be of the nesting variety. Formed or die-cut top sheets can be used in combination with the load-transfer spacer sheets

CROSS REFERENCE TO RELATED APPLICATIONS

CIP of applications Nos.: Ser. No. 11/082,984 filed Mar. 18, 2005 and Ser. No. 11/594,187 filed Nov. 8, 2006.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable

REFERENCE TO MICROFICHE APPENDIX

Not Applicable

BACKGROUND OF THE INVENTION

1. This invention is directed to a packaging system for multi-pack stackable structured packaging for shaped containers.

2. There exists a large family of taper-shaped containers, differing both in shapes and sizes, used for pourable or pumpable fluids, most of which containers are soft, thin-walled plastic bottles. Owing to the thin-ness of their soft, flexible walls these containers are subject, when loaded externally, to deformation with consequent stress cracking, so that they presently are transported in a substantially loose-packed condition within substantially rigid, fully enclosed cardboard cartons.

Cardboard packaging is used extensively in the Western world for an extremely wide range of goods. This “board”, primarily of the three-layer type having a corrugated core, is frequently used in a ‘once-off’ manner, and then either scrapped, or recycled. The adverse ecological burden that this represents is little recognised. The production, use and re-cycling of the vast quantities of material involved requires the ongoing destruction of forests and requires vast quantities of fuel (for transportation), water and power for initial production, and for recycling, when that is practiced.

In the present matter of global warming, vast quantities of green-house gas are generated in the manufacture and subsequent disposal or re-utilization of cardboard (board) packaging. Any effective diminution in the quantity of board required for packaging, or increase in its utilization by way of re-use represents a significant reduction in the generation of green-house gases, and can provide a highly desirable reduction in the rates of world-wide de-forestation.

A brief review of the background concerning the usage of corrugated cardboard (CC) establishes the following facts:

In the United States CC-fibre is re-cycled twice on average: in Europe it is recycled four times. [source—Barbara Crowell—Pack3 conference Brussels May 3-4, 1993]

In Asia CC is recycled so many times as to be significantly weaker and less water-resistant than US recycled fibre, so as to be unacceptable for further recycling.

The reduction by one Tonne of Corrugated Board can lead to representative cost savings:

-   -   Municipal Solid waste Management—$176; Municipal Wastewater         management—$7;     -   Value of reduced Greenhouse Gas emissions—$19. Totalling Direct         Savings $183.     -   A further indirect saving of $19 may also accrue.         The present invention, in common with the above-referred to         Applications, aims at providing integrated structural packaging         that particularly lends itself to being multi-tier stacked on a         pallet for purposes of handling, shipping, storage and display,         while minimizing the quantity of packaging material required to         achieve the desired structural characteristics.

In the above-referred patent applications the goods containers are primarily of substantially rigid, cylindrical form (including rectangular cylindrical sections), with the packaging having D-cut and other separators positioned between the respective containers, to provide mutual separation, combined with integration of the containers with the package, under the compressive effects of tensioned wrapping strap or straps.

In the subject family of thin-walled plastic containers, most such containers are non-cylindrical, being shaped generally with an upwardly modified cross section, both for aesthetic and for hand-held purposes, and also to facilitate their withdrawal from their moulds. This tapered formation, allied with the thin-walled flexible structure of the containers militates against their satisfactory immobilization within, and integration with the containing package, under the compressive influence of external strapping, as taught in the forementioned Applications.

BRIEF SUMMARY OF THE INVENTION

The present invention provides a packaging system for the bulk packaging of flexible walled containers of non-uniform section, wherein a plurality of the containers are mounted upon a tray, in secured relation thereto to form a package, having at least one integrating collar engaging at least some of the containers in secured, mutually spaced relation; and upwardly extending load transfer means to promote the load carrying capability of the package in the support of a superimposed like package or packages in stable, stacked relation therewith, usually for transportation by way of wooden pallets, which loads may be plasti-wrapped for transportation.

The subject containers may have upwardly tapering walls to provide a portion of the container with an upwardly diminishing cross section.

The subject containers may have screw cap closures; the subject integrating collar having a plurality of apertures in mutually spaced relation to receive a corresponding plurality of the cap closures extending in penetrating relation through the collar.

The subject collar apertures may have flexible edge portions to enter undercut portions of the container located below the caps, to thereby engage the caps and secure the integrating collar to the containers. The collar may be of corrugated board or paperboard. The load transfer means may be in the form of board separators extending between the containers and having upwardly extending portions projecting substantially coplanar with the tops of the containers, to provide co-planar load-receiving means as support for a superimposed package. The board separators are preferably of vertically oriented corrugated board.

The subject containers may be glued to the tray.

The subject containers may be positioned on the tray by way of upturned board portions of the tray engaging edge portions of the lower extremity of respective ones of the containers.

Selected adjoining ones of the subject containers may be joined by way of a low-tension adhesive.

The subject load transfer means may comprise upwardly extending partition means having the lower end portion thereof secured to the tray, and extending upwardly between adjacent ones of the subject containers, with an upper edge portion of the partition means located substantially coplanar (flush) with the tops of the container caps, in load sharing relation therewith.

The subject partition means may be convoluted when seen in plan view, with adjoining portions respectively extending laterally and longitudinally of the subject tray, in mutual stiffening relation.

The subject partition means may have first and second portions in mutually inclined, normal relation, each portion extending in interdigitated stiffening relation with an adjoining, normally extending portion.

The subject package may include low tension (frangible) glue as an attachment agent between package components and containers, and between adjoining containers, at their mutual contact areas.

One embodiment may have a planar die-cut top sheet, having a series of die-cut apertures having radiating cut-lines, for penetration and capture of the caps of the respective containers. A further series, of laterally and of longitudinally extending cut lines or slots receive upwardly projecting tab portions of the convoluted (“Z”) dividers. The shoulder portions of the separators adjoining the tabs support the undersurface of the top sheet, and the tabs project through the cut slots and extend above the top sheet, to be substantially coplanar with the top surfaces of the projecting caps of the containers.

A further embodiment provides a tray having slightly tapered walls, such that the trays may be nested. The top sheet may be dimensioned to fit into the base of the tray, enabling a number of trays and their associated top sheets to be packaged into a “solid” block for return shipping to the goods Supplier, for re-use. The tray wall height may be selected to match a predetermined number of top sheets, such as the five of a pallet stack.

The Z-spacers may pack flat with the trays and top sheets.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

Certain embodiments of the invention are described by way of illustration, without limitation thereto other than as set forth in the accompanying claims, reference being made to the accompanying drawings, wherein:

FIG. 1 shows a first group of five containers A through E, of non-uniform section;

FIG. 2 shows a second group of containers A through D of non-uniform section;

FIG. 3 shows a third group of containers A through C of less usual shape;

FIG. 4 is a plan view of a first embodiment package of containers, packaged in accordance with the present invention, and incorporating a load-bearing spacer;

FIG. 5 is a side elevation of the FIG. 4 package embodiment;

FIG. 6 is a perspective view of the spacer of FIGS. 4 and 5;

FIG. 7 is a plan view of a second embodiment package of containers incorporating a top locator/load transfer cover;

FIG. 8 is a perspective view of a further embodiment of a top locator/load transfer cover in an inverted position;

FIG. 9 is a plan view of a loaded tray, before application of the transfer cover of FIG. 8, with four partition members shown in their assembled condition;

FIG. 10 is a partial top perspective view of portions of a package having a planar die-cut top sheet, showing projecting container caps and upstanding spacer tabs;

FIG. 11 is a plan view of the FIG. 10 arrangement;

FIG. 12 is a perspective view of a nestable tray;

FIG. 13 is a perspective view of a top sheet matched to the FIG. 12 tray; and,

FIG. 14 is a perspective view of a portion of a store's trolley for use with nestable package components

DETAILED DESCRIPTION OF THE INVENTION

It will be understood by those skilled in the art that the above disclosure is directed primarily to specific embodiments of the present invention, and that the subject invention is susceptible of reduction to practice in other embodiments that fall within the scope of the appended claims.

Referring to the drawings, FIGS. 1, 2 and 3 illustrate a very small portion of an almost limitless assortment of plastic container ‘bottles’, many of which are “soft-walled”, and are suited for packaging in the presently disclosed high efficiency packaging, characterized by its integration of packaging components with the structure of the container, to form structural packages that are well adapted for multi-layer palletizing. It will be understood that ‘hard-walled’ containers, including other than plastic may also be susceptible of use within the present invention.

FIG. 4 shows a package 10 including six shaped containers 12 mounted in a tray base 14 and having a spacer 16 of corrugated board secured by way of insert tabs 18 to the bottom 20 and wall 21 of the tray base 14 (see also FIG. 6). The containers 12 are each secured by way of low-tension adhesive (not shown) to the package bottom 20. The abutting side surfaces of containers 12 may also be mutually adhered by way of small patches of ‘low-tensile’ (strength) adhesive (not shown).

A strap 17 may be used, which is positioned by corner slots 19 to engage and retain the ‘corner’ containers 12.

The top edge of the spacer 16 is substantially coplanar with the tops of the caps 24 of the containers 12 (see FIG. 5), to supplement the load-bearing capacity of the containers 12.

Referring to FIG. 7, in this package embodiment 25, a spacer such as 16 may be supplemented or replaced by a spacer/platform 26 shown in overlaid (but non-applied) relation with the base 14 and the containers 12. The spacer/platform 26 has a die-cut sheet portion 28 with score-cut holes 30 that are sized to receive and engage beneath the lower edges of the caps 24, so as to locate the top portions of the containers 12, when the spacer/platform 26 is pushed down over the underlying caps 24.

The spacer platform 26 has an upstanding peripheral rim 32 that projects upwardly to be flush with the tops of the container caps 24, so as to provide a supporting base for a superposed like package 10 or 25, which would overly the rim 32.

It will be understood that for the package embodiment 25 the spacer 16 would be made shorter, so as to be flush with the bottom surface of the sheet portion 28 when sheet 28 has been pushed down to engage beneath the caps 24.

The load strength of corrugated boards in a range of board weights has been tested, using specimens reinforced against buckling failure by having two adjoining areas being bent mutually at an angle of about 90 degrees to form a so-called Z-spacer, it being understood that the corrugations are edge-on to the direction of applied load, to provide optimum columnar strength.

Turning to FIGS. 8 and 9, a top locator/load transfer cover 40, shown inverted, and illustrated as being of moulded paper board, has eight score-cut holes 30 to receive and engage beneath the lower edges of container caps, such as the caps 24 of FIG. 5.

A central upstanding rib 42 of inverted U-section (when viewed in its inverted orientation of use) extends the length of the cover 40. The rib 42 is dimensioned to be substantially coplanar with the tops of the container cans (such as 24). Laterally extending ribs 44 of similar cross-section intersect with rib 42 at upstanding caps 46, the tops of ribs 44 being co-planar with the top of rib 42 and the caps 46, and also with the container caps 24, when assembled.

The illustrated undersurface of the cover 40 forms passages 45 into which dividers 48 are slotted. The dividers 48 extend to the floor of the tray or base upon which the package contents would stand, to provide a contiguous, reinforced support structure. The dividers 48 and the interior width of the ribs 42, 44 may be dimensioned to provide a tight slide-in fit, or the dividers may be spot-glued in place, or located by ‘toe tabs’ fitted into tray recesses.

It will be understood that different arrangements and smaller numbers of dividers may be used, in accordance with the need for separation of containers, and the desired load bearing capacity of the combined contents and package to meet pallet load requirements. Referring to FIGS. 10 and 11, the embodiment 101 has a bottom tray 102 with eight containers 104, only one of which is fully represented. A top sheet 106 has eight container caps 108 projecting above, and engaged by respective die-cut cap apertures of the sheet 106.

Aperture tabs 110 are engaged beneath the lower edges of the caps 108, to secure the top sheet 106.

Ten upstanding tab portions 112 project from die-cut tab apertures of the top sheet 106. The upper edges of the tab portions 112 are coplanar with the tops of the container caps 108, to provide support to the tray 102 of an overlying like package.

The dividers 114 from which the tab portions 112 extend are supported by the tray 102 of the package, such that when packages 110 are stacked five-high as part of a pallet load, the dividers 114 and their associated projecting tab portions 112 provide substantially continuous columnar support from the bottom tray to the top of the stack of packages, as reinforcement to the load bearing capacity of the containers 104 and their respective caps 108, which also form contiguous columnar supports from the bottom tray to the top of the package stack

Turning to FIGS. 12, 13 and 14: a stackable tray 120, has symmetrical sloped sides and ends that provide a shallow ‘draw’ angle, to enable it to be nested with like trays 120, having the associated top sheets sized to the size of the bottom tray, so as to fit within the nested trays, and to fill the top tray to its upper edge, to provide a strong return package. The tray 120 is illustrated as having a slot-indented bottom, to engage the bottom of the Z-spacers, which may be provided with shallow, bottom-edge tabs to fit the slot indents. The trays 120 and top sheets 122 each have an oriented peg-slot 121, 123 that enables their ready separation by store shelf stockers, using a cart 124 having correspondingly oriented pegs 125, 127. These pegs 125, 127 may be bayonet-mounted to the cart, such that a quarter twist will free the respective peg from the cart, enabling the ready downward and unobstructed removal of the trays 120 and top sheets 122 from off the pegs 125, 127. The dividers 114 may be flattened and packaged separately for return, or packaged to the nested trays when the sizes are compatible. 

1. A composite package containing a plurality of substantially identical containers of goods, for transportation, storage and display, said package having a lower portion to receive said goods containers in assembled, mutually organized relation thereon; first positioning means to immobilize said containers in relation to said package lower portion; divider means interposed in spacing relation between predetermined ones of said containers, second positioning means to secure the upper portions of said containers in mutually fixed relation, said second positioning means having upper portions of predetermined load-bearing capacity extending upwardly to be substantially coplanar with the tops of said containers, and retaining means securing the elements of said package in mutually secured relation to form a stable, load-bearing structural unit for stacking in a plurality of self-supporting layers.
 2. The composite package as set forth in claim 1, said first positioning means consisting of an adhesive securing individual ones of said containers to said package lower portion.
 3. The composite package as set forth in claim 1, said first positioning means consisting of raised surface portions of said package lower portion, located to contact lower edge portions of at least some of said containers in positioning engagement therewith.
 4. The composite package as set forth in claim 1, having a securing strap attached in compressive, positioning relation with selected portions of said package.
 5. The composite package as set forth in claim 1, said retaining means comprising an upper tray member engaging upper portions of said containers in predetermined positioned relation, said upper tray member having load bearing upper support surface portions, in use to receive a further package in supported relation thereon.
 6. The composite package as set forth in claim 1, said containers each having an upper, closure cap, said divider means having at least one portion of corrugated board extending in supported relation from said package lower portion to a position substantially coplanar with the tops of said containers, said corrugated board divider means having the corrugations thereof positioned edgewise to the anticipated direction of applied downward compressive loading.
 7. The composite package as set forth in claim 5, said upper tray member having laterally and longitudinally extending hollow ribs, and corrugated board divider means extending from said package lower portion to engage said ribs in load-transfer relation between said package lower portion and said upper tray member.
 8. The composite package as set forth in claim 7, said element securing retaining means comprising a plurality of mutually spaced apertures to receive respective cap portions of said containers in entered, engaged relation therein.
 9. The composite package as set forth in claim 1, said retaining means comprising an upper sheet member having apertures to receive closure cap members of said containers in secured penetrating relation therethrough; said upper sheet member having a plurality of slots in predetermined positioned relation to receive upwardly extending tab portions of said divider means in penetrating relation therethrough.
 10. The composite package set forth in claim 9, said closure cap members and said upwardly extending tab portions having their uppermost surfaces in substantially co-planar relation, to provide load bearing upper support surfaces, in use to receive a further package in supported relation thereon.
 11. The composite package as set forth in claim 6, said package lower portion consisting of a tray having side walls and a bottom, said side walls being outwardly tapered to form a nesting draw, whereby said tray may be nested with other like trays, to form a compact package for ready shipment.
 12. The composite package as set forth in claim 11, said second positioning means consisting of a planar cover sheet sized to fit within said side walls, upon said tray bottom, said cover sheet having apertures to receive projecting upper portions of said container in secured penetrating relation therethrough; said cover sheet having a plurality of slots in predetermined positioned relation to receive upwardly extending tab portions of said divider means in penetrating relation therethrough.
 13. The composite package as set forth in claim 12, said tray side walls being of predetermined height to accommodate a predetermined number of said cover sheets in flush-fitting relation within a said tray.
 14. A composite package for secure shipping, having a plurality of walled tray members in mutually nested relation, the uppermost said tray member containing a plurality of substantially planar sheets in mutually stacked relation within said tray; said substantially planar sheets each having apertures extending therethrough, arranged in predetermined mutually spaced relation, in use to receive load transfer members in projecting relation through said planar sheet. 